Suspension assembly and method of manufacture

Abstract

Methods, assemblies, and/or the like are provided. In accordance with various embodiments of the present disclosure there is provided a suspension assembly including a suspension frame having a lower band including one or more band holes configured to provide ventilation to a wearer of the suspension frame; and an upper band having one or more slots; and a pad overmolded onto the suspension frame, wherein the pad has one or more pad holes, wherein the one or more pad holes are configured to be aligned with the one or more slots such that the one or more pad holes are configured to provide ventilation to the wearer of the suspension frame. In some embodiments, the pad is overmolded onto the upper band of the suspension frame. In some embodiments, the suspension frame is a single piece including the lower band and the upper band.

1 . A method of manufacturing, the method comprising:
 injecting, by a first injection unit, a first material onto a mold defining a suspension frame, wherein the suspension frame comprises:
 a lower band comprising one or more band holes configured to provide ventilation to a wearer of the suspension frame; and 
 an upper band comprising one or more slots; 
   rotating the mold; and   injecting, by a second injection unit, a second material onto the suspension frame such that the second material forms a pad overmolded on the suspension frame.   
     
     
         2 . The method of  claim 1 , wherein the pad is overmolded onto the upper band of the suspension frame. 
     
     
         3 . The method of  claim 1 , wherein the suspension frame is a single piece comprising the lower band and the upper band. 
     
     
         4 . The method of  claim 1 , wherein the suspension frame comprises one or more flanges comprising one or more flange connection slots, wherein the one or more flange connection slots are configured to receive one or more fasteners to attach the suspension assembly to a helmet. 
     
     
         5 . The method of  claim 1 , wherein the first material is composed of high-density polyethylene or polyamide 6. 
     
     
         6 . The method of  claim 1 , wherein the pad is a sweatband having moisture-wicking properties. 
     
     
         7 . The method of  claim 6 , wherein the second material is composed of a thermoplastic elastomer (TPE), thermoplastic vulcanizates (TPV), or Thermoplastic Poly Urethane (TPU). 
     
     
         8 . The method of  claim 1 , further comprising attaching the suspension frame to a helmet. 
     
     
         9 . The method of  claim 8 , wherein the helmet is a hard hat. 
     
     
         10 . The method of  claim 1 , wherein injecting, by the second injection unit, the second material onto the suspension frame such that the second material forms the pad overmolded on the suspension frame comprises forming one or more pad holes aligned with the one or more slots. 
     
     
         11 . The method of  claim 1 , wherein:
 the first material is selected from the group consisting of high-density polyethylene, polyamide 6, and combinations thereof; and   the second material is selected from the group consisting of thermoplastic elastomer (TPE), thermoplastic vulcanizates (TPV), Thermoplastic Poly Urethane (TPU), and combinations thereof.   
     
     
         12 . The method of  claim 1 , wherein injecting, by the second injection unit, the second material onto the suspension frame comprises overmolding the second material onto the suspension frame. 
     
     
         13 . The method of  claim 12 , wherein overmolding the second material onto the suspension frame comprises overmolding the second material onto the suspension frame in a one step, two shot injection overmolding process. 
     
     
         14 . The method of  claim 1 , wherein the lower band and the upper band are substantially semi-circular bands that form a substantially circular or oval-shaped suspension frame. 
     
     
         15 . The method of  claim 1 , wherein the suspension frame is configured to wrap around an individual's head.